PROJECT REPORT

A REPORT ON:VOCATIONAL TRAINING

AT
DENSO GREATER NOIDA
PREPARED BY:SACHIN BHATI (13/IME/048)
THIRD YEAR
MECHANICAL ENGINEERING
GAUTAM BUDDHA UNIVERSITY
GREATER NOIDA, GAUTAM BUDDHA
NAGAR
UTTAR PRADESH

ACKNOWLEDGEMENT
First of all, i convey my sincere thanks to Mr. SATPAL
SHARMA Head of Department (ME Branch) for granting
me the training letter to do my summer training at DENSO Gr.
Noida.
I acknowledge with deep sense of gratitude, the guidance and
knowledge I received from the pioneers of the industry. This
report wouldnt have been possible without the generous help
given to me by the people, who helped me in making this,
project a learning experience.
Heartiest appreciation goes to my parents for their
encouragement and advice that helped me enormously in
completing this project.

Date:-01 /08/ 2016

SACHIN BHATI
(13/IME/048)
ME 7th SEM.
GBU (GREATER NOIDA)

DENSO
Denso Corporation is a global automotive components manufacturer
headquartered in the city of Kariya, Aichi Prefecture, Japan.
After becoming independent from Toyota Motors, Nippon Denso Co.
Ltd. was founded in 1949. About 25% of the company is owned
by Toyota Motor. Despite being a part of Toyota Group of
companies, as of year ended March 2016, sales to Toyota Group
accounts for less than 50% of the total revenue (44% of the revenue
originate from other car manufacturers in Japan, Germany, U.S. and
China). Currently, Denso ranks the fourth largest auto parts supplier.
As of 2013, Denso Corporation consisted of 184 subsidiaries (68 in
Japan, 34 in the Americas, 34 in Europe and 48 in Asia/Oceania) with
a total of 132,276 employees. The company is further escalating its
global production structure by establishing manufacturing complexes
in India, Mexico and Indonesia in order to accommodate further
global demand for their products. In 2013 Denso was listed at #242
on the Fortune 500 list with a total revenue of $43.1 billion.

SALES
The company is known for developing and manufacturing various
auto-parts including but not limited to: Gasoline/Diesel Engine
Components, Hybrid Vehicle Components, Climate Control Systems,
Instrument Clusters, Air-Bag Systems, Pre-Crash Radar Systems and
Spark Plugs. Moreover, Denso also develops and manufactures nonautomotive components such as Household Heating Equipments,
Industrial Robots and QR Code. The Denso Industrial Robot gained
wide public attention in Japan when it conducted a game
of Shogi (Japanese Chess) against professionals players.
In 2014, Denso's global sales were distributed as follows:

Thermal Systems 30.4%

Powertrain Control Systems 35.0%

Electronic Systems 15.3%

Electric Systems 9.4%

Electric Motors 7.0%

Other Automotive Products 1.4%

Industrial Systems, Consumer Products 1.1%

Other Non-Automotive Products 0.4%

DENSO MANUFACTURING
ALTERNATOR
STARTER
FUEL PUMPS
IGNITION WIRE SETS
FILTERS
SPARK PLUGS

ALTERNATORS
An alternator is an electrical generator that converts mechanical
energy to electrical energy in the form of alternating current. For
reasons of cost and simplicity, most alternators use a
rotating magnetic field with a stationary armature. Occasionally,
a linear alternator or a rotating armature with a stationary magnetic
field is used. In principle, any A C electrical generator can be called
an alternator, but usually the term refers to small rotating machines
driven by automotive and other internal combustion engines. An
alternator that uses a permanent magnet for its magnetic field is called
a magneto. Alternators in power stations driven by steam turbines are
called turbo-alternators. Large 50 or 60 Hz three phase alternators in
power plants generate most of the world's electric power, which is
distributed by electric power grids.

Principle of Operation of Alternator

A conductor moving relative to a magnetic field develops
an electromotive force (EMF) in it (Faraday's Law). This emf
reverses its polarity when it moves under magnetic poles of
opposite polarity. Typically, a rotating magnet, called
the rotor turns within a stationary set of conductors wound in
coils on an iron core, called the stator. The field cuts across the
conductors, generating an induced EMF (electromotive force),
as the mechanical input causes the rotor to turn.
The rotating magnetic field induces an AC voltage in the stator
windings. Since the currents in the stator windings vary in step
with the position of the rotor, an alternator is a synchronous
generator.
The rotor's magnetic field may be produced by permanent
magnets, or by a field coil electromagnet. Automotive
alternators use a rotor winding which allows control of the
alternator's generated voltage by varying the current in the rotor
field winding. Permanent magnet machines avoid the loss due
to magnetizing current in the rotor, but are restricted in size,
due to the cost of the magnet material. Since the permanent
magnet field is constant, the terminal voltage varies directly
with the speed of the generator. Brushless AC generators are
usually larger than those used in automotive applications.
An automatic voltage control device controls the field current to
keep output voltage constant. If the output voltage from the
stationary armature coils drops due to an increase in demand,

more current is fed into the rotating field coils through

the voltage regulator (VR). This increases the magnetic field
around the field coils which induces a greater voltage in the
armature coils. Thus, the output voltage is brought back up to
its original value.
Alternators used in central power stations also control the field
current to regulate reactive power and to help stabilize the
power system against the effects of momentary faults. Often
there are three sets of stator windings, physically offset so that
the rotating magnetic field produces a three phase current,
displaced by one-third of a period with respect to each other.

Alternator (automotive)
Alternators are used in
the battery and to power
its engine is running.

modern automobiles to charge

the electrical system when

Until the 1960s, automobiles used DC dynamo generators

with commutators. With the availability of affordable silicon
diode rectifiers, alternators were used instead. This was
encouraged by the increasing electrical power required for cars
in this period, with increasing loads from larger headlamps,
electric wipers, heated rear windows and other accessories.

PARTS OF ALTERNATOR

1. Housing
Re-tapped to OE standards and damage-checked for heat
warping, corrosion, or improper surface alignment.

2. Stator
The stator is the stationary part of a rotary system, found
in electric generators, electric motors, sirens,
or biological rotors.
3. Rotor
A rotating part of a mechanical device, for example in an
electric motor, generator, alternator or pump.
4. Bearing
Ball Bearings are commonly used in the vehicle. They are
found in everything from the Alternator to the Rear End. This
type of bearing can handle both radial and thrust loads and are
typically found in situations where the load is relatively small.
5. Slip Ring
A slip ring is an electromechanical device that allows the
transmission of power and electrical signals from a stationary
to a rotating structure
6. Voltage Regulator
This is an electrical component used to maintain the proper
charge state of the battery by regulating alternator output.
7. Rectifier
A rectifier is an electrical device that converts alternating
current (AC), which periodically reverses direction, to direct
current (DC), which flows in only one direction.
8. Hardware
100% stripped and replated.

STARTER
A starter (also self starter, self, or starter motor) is an electric
motor, pneumatic motor, hydraulic motor, an internal-combustion
engine in case of very large engines or other device used for rotating
an internal-combustion engine so as to initiate the engine's operation
under its own power.
Internal-combustion engines are feedback systems, which once started
rely on the inertia from each cycle to initiate the next cycle. In a fourstroke engine, the third stroke releases energy from the fuel, powering
the fourth (exhaust) stroke and also the first two (intake, compression)
strokes of the next cycle, as well as powering the engine's external
load. To start the first cycle at the beginning of any particular session,
the first two strokes must be powered in some other way than from
the engine itself. The starter motor is used for this purpose and is not

required once the engine starts running and its feedback loop becomes
self-sustaining.

PARTS OF STARTER

1. Solenoid Coil
A starter solenoid (or starter relay) is the part of
an automobile which switches a large electric current to
the starter motor

2. Terminal Bolts
100% re-plated with copper.

3. Commutator
A commutator is a moving part of a rotary electrical switch in
certain types of electric motors and electrical generators
that periodically reverses the current direction between the
rotor and the external circuit..

4. Housing
Re-tapped to OE standards and damage-checked for heat
warping, corrosion or improper surface alignment and
refinished.

5. Pinion Gear
A pinion is a round gear used in several applications

6. Field Coil
inspected, striped and high voltage tested.

7. Armature
the rotating coil or coils of a dynamo or electric motor.

FUEL PUMPS

1. Armature
Ultra-high balanced to minimize noise and vibration.

2. Turbine Technology
Delivers fuel with minimal pressure pulsation for quieter
operation.

3. Check Valve
Maintains consistent system pressure for superior hot fuel
handling characteristics.

4. Relief Valve
Protects the fuel delivery system.

5. Choke Coils
Minimize radio interference.

6. Brushes
Designed for durability, efficiency, and low-resistance operation.

FILTERS
AIR FILTERS

Precision molded sealing surfaces ensure a quality fit

 High density, multi-fiber media and optimal pleat design

Heat-resistant frame, developed to DENSOs First Time Fit

DENSO'S INNOVATIVE THREE LAYER DESIGN

1. Course layer
catches large dirt and dust particles.

2. Intermediate layer
catches medium size dirt and dust particles.

3. Fine Layer
catches fine particles of dirt and dust.

FEATURES
High airflow rate improves performance and fuel economy.
Superior dust holding capacity increases filter life.
Maxiumum efficiency reduces engine wear.

BENEFITS

Easy installation with a factory quality fit.

Prevents abrasive particulate matter from entering the engine

reducing engine wear.

Replacing a clogged air filter can improve engine performance.

 CABIN AIR FILTERS

FEATURES
Filter designed to trap contaminants before they enter the
vehicle cabin.
Premium-quality filter media stops particulates down to 0.001
microns.
Fleece material used contains up to five individual layers for
super-fine filtration.

BENEFITS

Traps soot, dirt, and pollen to provide greater passenger

comfort

Maximum airflow, minimum air noise

First Time Fit assures easy replacement, even for Do-It.

 OIL FILTERS

Filter media lasts longer than competitors' standard grade filters.

Durable steel housing resists distortion

 Efficient paper media

Reliable anti-drain back valve
Special formulated rubber O-ring, delivering a leak resistant seal
Reliable pressure relief valve opens when filter is at maximum
capacity ensuring a continuous flow.

1. Efficient Paper
protects engines against contaminants.

2. Silicon Anti-Drainback
prevents rough starts caused by oil draining out of the engine while
vehicle is turned off.

3. Pre-Lubricated Molded O-Ring

seals better than gaskets used by other brands.

FEATURES
Heavy-duty steel case resists distortion
Pre-lubricated molded o-ring provides superior sealing over generic
filters
Unique Torque Stopper design prevents leaks from under torquing

BENEFITS

Dual-layer filtration media for greater oil filtration

Silicone anti-drainback valve prevents rough starts

Traps contaminants for increased engine protection

IGNITION WIRE SETS

Identical OE End Caps

Designed to "click" into place for easy installation and a secure
fit. This allows the installer to "feel and hear" that a solid
connection has been made, even when the connection is in a
difficult-to-see location.

Strong Connections
Through a patented process, the terminals are attached to
provide an extremely strong connection ensuring the cable and
boot will not separate during removal and installation.

Pre-cut to Exact Lengths

Each wire in the set is pre-cut to exact length so the wire sets
are ready to install right out of the box.

All-Silicone Wires
The 7 and 8mm ignition wires are SAE J2031 Class E rated,
the highest quality wire used in the industry. These wires can
withstand temperatures from -40 to 428 F and pass tests
covering everything from electrical properties to shrinkage to
chemical resistance and accelerated life testing.

SAE Wire
C
D
Classification
Thermal Overload
155 C /
180 C /
Test Temp.
311 F
356 F
Low Temperature
-30 C /
-30 C /
Test
-22 F
-22 F
High Temperature
120 C /
155 C /
Test Temp.
248 F
311 F
Low Temp.
20 C / -4 F -20 C / -4 F
Resistivity Test

E
220 C / 428 F
-40 C / -40 F
180 C / 356 F
-30 C / -22 F

1. High temperature "Class E" silicone jacket to withstand heat, cold,

chemicals and moisture.
2. Reinforcing member for added strength and terminal retention.
3. Silicone insulation for superior dielectric and heat performance.
4. Conductive silicon layer for high temperature performance and
EMI/RFI noise suppression.

5. Fiberglass braid for maximum strength.

6. Carbon impregnated fiberglass core for superior support
conductivity.
7. Core reinforced with KEVLAR.
8. Layer impregnated with Ferrite.
9. Wire-wound layer to suppress EMI/RFI noise.

BENEFITS

Superior dielectric and thermal qualities

Factory-original fit, appearance, and performance

World-class chemical and oil resistance

ALTERNATOR REMOVAL AND

INSTALLATION
Removal Information
1. Disconnect the negative battery cable from the vehicle.
CAUTION: Personal injury or damage to the vehicle or its
components may occur if this step is not performed.
2. Identify each wire connection and note the location of each on
the alternator.
3. Disconnect the wires from the alternator.
4. Loosen the alternator pivot bolt. Do not remove the bolt at this
time.
5. Loosen the tension assemblys lock nut or bolt and turn the
adjustment bolt so that drive belt tension is reduced far enough
to allow belt removal. Some vehicles may be equipped with an
automatic, springloaded tensioner. Rotate the spring-loaded
tensioner using the appropriate tool far enough to allow drive
belt removal.
6. Remove the drive belt(s) from the alternator.
7. Support the alternator and remove the bolts holding the
alternator in place. Set the bolts and alternator aside. Be sure to
note bracket orientation and fastener length and location before
removing the alternator.

8. Inspect the condition of the wiring and connectors. Inspect for

frayed wire ends, continuity, loose or broken connectors,
corrosion and pliability. Repair or replace as necessary.

Installation Information
1. Physically compare the replacement alternator to the original.
Compare the case and pulley offsets, pulley size and type, pivot
and adjustment hole locations and wire connector locations or
rear housing clocking with the original alternator.
2. Install the mounting bracket(s). Do not completely tighten the
bolts at this time.
3. Support the alternator and fasten it into position. Do not
completely tighten the bolts at this time.
4. Install the drive belt(s). If the drive belt(s) was found to be
worn, stretched, cracked, oily or glazed during the charging
system inspection, replace the belt(s).
5. Set the belt tension while tightening the mounting and adjusting
bolts. Be sure to set the belt tension and torque the mounting
bolts to the vehicle manufacturers recommended specifications.
CAUTION: DO NOT pry or hit the alternator housing to adjust
belt tension.
6. Check the drive belt alignment between the alternator pulley and
drive pulley(s). Be sure there is no interference between the
drive belt(s) and other components.
7. Re-connect the wire connector(s) to their proper location on the
alternator. Be sure there is no interference between the wire
harness and other components.

8. Re-inspect that all components are correctly installed, all

threaded fasteners properly torqued and there is no interference
between components.
9. Re-connect the battery negative cable.
10.
Start the engine and be sure there is no interference
between components. Let the engine idle for 10 minutes to
break-in the drive belt(s). Readjust the drive belt(s) using the
used tension specification.
11.
Shut the engine off and re-inspect that all components are
correctly installed, all fasteners properly torqued and there is no
interference between components.
12.
Re-test the charging system to verify it is performing to the
vehicle manufacturers specifications.

STARTER REMOVAL AND INSTALLATION

Removal Information

1. Disconnect the negative battery cable from the vehicle.

CAUTION: Personal injury or damage to the vehicle or its
components may occur if this step is not performed.
2. Identify each wire connection and note the location of each on
the starter.
3. Disconnect the battery positive cable from the starter motor or
the starter solenoid if the solenoid is attached to the starter
motor.
4. Disconnect the starters control circuit wiring from the starter
solenoid if the solenoid is attached to the starter motor.
5. Loosen the starter mounting bolts. Do not remove the bolts at
this time.
6. Support the starter and remove the bolts holding the starter in
place. Set the bolts and starter aside. Be sure to note fastener
size and location when removing from the starter.
7. Inspect all the flywheel/flex plate teeth. Perform the inspection
through the starter mounting port if an inspection plate is not
available.

Installation Information

1. Physically compare the replacement starter to the original.

Compare the case, nosecone and mounting offsets, mounting
hole locations, drain tube location, wire connector locations and
nose cone clocking with the original starter.
2. Support the starter and fasten it into position. Torque the bolts to
the vehicle manufacturers specification.
3. Re-connect the starters control circuit wiring to the starter
solenoid if the solenoid is attached to the starter motor. Be sure
there is no interference between the wire harness and other
components. Torque all threaded fasteners to the vehicle
manufacturers specification.
4. Re-connect the battery positive cable to the starter motor or the
starter solenoid if the solenoid is attached to the starter motor.
Torque all threaded fasteners to the vehicle manufacturers
specification.
5. Re-inspect that all components are correctly installed, all
threaded fasteners properly torqued and there is no
interference between components.
6. Re-connect the battery negative cable. Torque all threaded
fasteners to the vehicle manufacturers specification.
7. Check the starter for proper operation.